U.S. DOE reinforces its commitment to advanced batteries for EVs with new technology Hub
The U.S. Department of Energy on Nov. 30 announced it will establish a major advanced-battery research center on the campus of Argonne National Laboratory outside Chicago. The Batteries and Energy Storage Hub, also called the Joint Center for Energy Storage Research (JCESR). Establishment of the Hub is tied to the award of DOE funding of up to $120 million for a research team led by Argonne and consisting of additional national labs, universities, and private companies, the latter consisting of Dow Chemical Co., Applied Materials Inc., Johnson Controls Inc., and Clean Energy Trust. JCESR will integrate independent research being done by the participating entities into a coordinated effort. It is the fourth Hub established by the DOE since 2010 (the others address nuclear energy, building efficiency, and fuels derived from sunlight), and like the others it is modeled on the "strong scientific management characteristics of the Manhattan Project" and similarly renowned enterprises. Research will apply to multiple industries, not just automotive.
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Argonne scientist Ira Bloom examines a metallographic sample using an optical microscope to determine its microstructure in the laboratory's Battery Post-Test Facility. This information helps researchers learn what chemical and physical changes have occurred during the aging of battery materials.
Motiv ePCS to power heavy electric trucks in Chicago
San Francisco Bay Area-based startup Motiv Power Systems has been chosen to supply its scalable electric Powertrain Control System (ePCS) to the City of Chicago for 20 all-electric garbage trucks, under an exclusive five-year, $13.4 million contract. The City of Chicago operates 600 garbage trucks in total. The ePCS uses off-the-shelf batteries and motors that can be configured to power medium-duty to Class 8 heavy-duty EV trucks, weighing from 15,000 to 52,000 lb (6800 to 23,500 kg). This design approach can cut operating costs by 50% over an eight-year period, according to Motiv. The company, which was founded in 2009, has been validating its ePCS since March 2012 with an all-electric pilot bus. Funded by a grant from the California Energy Commission, the 20-passenger bus contains five battery packs (125 kW·h) providing a range of more than 120 mi (193 km) on a single charge. The Motiv EV refuse trucks planned for Chicago will use the same ePCS system as the pilot bus, but with a larger motor and 10 battery packs, and will also employ an electric motor to drive the hydraulics system. Motiv will work with partner Detroit Chassis to install the ePCS onto a standard refuse chassis; Loadmaster will provide the truck bodies. Weighing 52,000 lb (23,500 kg), the EV refuse trucks will reportedly have a range of more than 60 mi (97 km), with a total energy storage of 200 kW·h. (Go to www.sae.org/mags/sohe/11486 to read about another recent electrified refuse truck project.)
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Weighing 52,000 lb, the Motiv-powered electric refuse trucks in Chicago will have a range of more than 60 mi (97 km), with a total energy storage of 200 kW·h.
SAE introduces certification for engineers involved in vehicle electrification
SAE International announced Nov. 14 that it will implement a personnel certification program that enables engineers, product development technicians, and associated personnel to earn a certificate of competency or certification in the area of vehicle electrification (VE). Through a process that engaged a group of auto industry subject-matter experts, a VE body of knowledge was developed and segmented into three distinct levels to meet the needs of specific personnel. Exam questions were generated to align with the body of knowledge to address each of the three levels. The VE Fundamentals and Safety Certificate of Competency is designed for individuals who require training and validation of knowledge in general electrified vehicle architectures, basic electricity and electronics, and critical safety precautions and procedures. Job roles include manufacturing personnel, procurement, sales, management, and engineering undergraduate students. This credential requires completing an online training course and passing an online exam. The VE Professional Certification level, due to launch in February 2013, is designed for individuals to validate mastery of knowledge in general VE safety and all major VE systems. Job roles include engineers, technicians, and other technical personnel assigned to electrified vehicle platforms but not involved with direct design of VE systems. Passing an online exam results in certification that remains in force for three years. The VE Engineer/Scientist Certification level will launch in March 2013 and is for individuals to validate mastery of knowledge in the science and design of all major VE systems. Job roles include engineers and R&D scientists engaged in focused research or product design of VE systems such as battery packs, motors, power electronics, and systems integration. Passing an online exam also results in certification that remains in force for three years.
KLD Energy, Cenntro to develop specialized EVs for U.S., China
KLD Energy Technologies, Inc., an Austin, TX-based developer of electric propulsion and generation systems, has teamed up with Cenntro Group Ltd., a developer of diesel and liquid-propane powertrains for agricultural, transportation, and construction equipment, to jointly develop four-wheel electric vehicles (EVs) that will incorporate KLD’s EV drive system technologies. The companies plan to initially focus on the U.S., Europe, and China, with the launch of the Utility Electric Vehicle, an on- and off-highway work and maintenance vehicle; the low-speed Neighborhood Electric Vehicle; and the Intra-city Logistic Vehicle, a compact delivery vehicle. Cenntro Group owns a number of operations in China and the U.S., including Zenith Power Products, LLC and Xinchang Cenntro Machinery Co., Ltd., and is a major shareholder of Sinomachinery Group Ltd. In related news, KLD and Samsung SDI also recently entered into a cooperative relationship to jointly develop battery systems that will incorporate Samsung SDI’s lithium-ion battery cells and KLD’s EV drive technologies.
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KLD’s EV drive system—comprised of the battery pack, the electric motor, and the motor controller—is applicable in a range of products, including motorcycles and scooters, three- and four-wheel on- and off-highway vehicles, and equipment for wind-energy generation.
Eaton, NREL team to reduce hybrid-electric-vehicle battery size
Eaton Corp. is developing a power control system for hybrid-electric vehicles (from passenger cars to commercial vehicles) with the goal of reducing by 50% the size of the battery needed. The company on Aug. 27 announced that the work is part of a $2.8 million project funded jointly by Eaton and the U.S. Department of Energy, the latter of which is contributing $2 million. The project is being led by Eaton's Innovation Center team in Southfield, MI, which will work with a team from the DOE's National Renewable Energy Laboratory (NREL)—the former offering expertise in intelligent power management and the latter expertise in battery modeling and prognostics. Specifically, the project aims to significantly downsize the battery through a combination of duty-cycle learning and model-based supervisory optimal control design. Using advanced physics-based battery models developed in partnership with NREL, the hybrid vehicle supervisory controller dynamically balances fuel economy and the health of the downsized battery pack to maximize vehicle performance while minimizing the impact on battery life.
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Using advanced physics-based battery models developed in partnership with NREL, the hybrid vehicle supervisory controller dynamically balances fuel economy and the health of the downsized battery pack.
Upcoming Volvo communication system services trucks remotely
In 2013, Volvo Trucks plans to release Telematics Gateway, a new software-based system that enables service technicians to evaluate trucks while they are on the road. The system will be able to access a truck’s information, including diagnostic trouble codes and mileage, over a wireless connection. Wear and tear on brake pads, batteries, and other elements of the vehicle can be detected remotely, which means fewer unnecessary trips to the workshop. “Today when we service a truck, we estimate a planned driving condition, but then the customer may use it more and drive in more heavy conditions,” said Christian Gustavsson, head of service at Volvo Trucks. “Now we can actually read out the usage from the truck so we can service the truck when it is really necessary.” The system will issue a warning if wear reaches a critical level, alerting the service technician to contact the customer and schedule a service. This increases the truck’s uptime and helps avoid unplanned maintenance stops. An informational video is available from Volvo Trucks on YouTube: http://www.youtube.com/watch?v=FmOYiOIF7lY&list=UUkKEthtUQHmBqIYZTHyfXoA&index=0&feature=plcp.
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Illustration of how Volvo Trucks' new Telematics Gateway works.
EU adopts two regulations on truck safety
The European Union in April adopted two regulations designed to enhance the safety of trucks with a gross vehicle weight exceeding 3500 kg and buses with more than eight passenger seats, according to InterRegs, an online resource for global vehicle safety and emissions regulations. One specifies the technical requirements and test procedures for advanced emergency braking systems (AEBS) that detect the possibility of a collision with a preceding vehicle; warn the driver by a combination of optical, acoustic, or haptic signals; and if the driver takes no action, automatically apply the vehicle’s brakes. The regulation also specifies two levels of performance to be achieved by AEBS. Fitment of AEBS meeting the "level 1" performance requirements becomes mandatory from Nov. 1, 2013 for new types of vehicles and from Nov. 1, 2015 for all new vehicles. The compliance dates for "level 2" are Nov. 1, 2016 for new types of vehicles and Nov. 1, 2018 for all new vehicles. The other regulation specifies the technical requirements and test procedures for lane departure warning systems (LDWS) that detect unintentional drift of the vehicle out of its travel lane and warn the driver by a combination of optical, acoustic, or haptic signals. Fitment LDWS becomes mandatory from Nov. 15, 2013 for new types of vehicles and from Nov. 1, 2015 for all new vehicles. Both regulations contain a list of specific vehicle types, such as urban buses and off-road vehicles, that are exempt. "New types of vehicles" are models being launched for the first time, and "new vehicles" are new vehicles being registered for the first time.
NHTSA proposes ESC for trucks and buses
NHTSA (U.S. National Highway Traffic Safety Administration) on May 16 proposed a rule to require that new large commercial truck tractors and buses be equipped with an electronic stability control (ESC) system. If and when the proposed rule is adopted, the mandate would take effect two years later for all new typical 6 x 4 truck tractors and four years for severe-service tractors and tractors with four or more axles. In justifying the lead times, NHTSA noted that there are only two suppliers of ESC systems for truck tractors and large buses: Bendix and WABCO. It said the current rate of ESC installation on new truck tractors is 18%.
San Fran gets its first public hydrogen fueling station (video)
In a boost to the future of fuel-cell technology, Linde North America has announced operations start-up of the first public hydrogen fueling station in the San Francisco Bay area. It offers fueling at 350 and 700 bar, the latter providing a refill time for a fuel-cell bus comparable to that of a diesel bus. Located in Emeryville, the station is one of two being supplied by Linde to AC Transit, which is a coalition of regional transport partners serving 7 million people in the Bay Area. The other station, in Oakland, is expected to begin operations in 2013. The Emeryville station was unveiled in a dedication ceremony April 10. It serves 12 fuel-cell buses operated by AC Transit, as well as privately owned fuel-cell passenger vehicles. (See video of the station here.)
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With technology from Linde North America, the station can dispense hydrogen at up to 5 kg/min (11 lb/min)—comparable to the rate at which diesel buses are refueled. The facility also features hydrogen production capability.
Azure Dynamics seeks future beyond bankruptcy (video)
Azure Dynamics, a developer and integrator of hybrid-electric and electric components and powertrain systems for commercial vehicles, has filed for bankruptcy. It plans to stay in business and reorganize. "We're really optimistic that we'll come out of this," said company spokesman Mike Elwood. All work at its global branches, including Oak Park, MI, has been "migrated" back to the company's home base in Burnaby, British Columbia, he said. Azure supplies the electric drive system for several commercial vehicles, including the Ford Transit Connect Electric. Elwood told AEI on March 29 that the company is in talks with its customers and hopes to have things "sorted out in a few days" in terms of whether it can restart production for the Transit Connect Electric and other products. (Video shows how Azure's electric drivetrain and related components are fitted to the vehicle)
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The Ford Transit Connect Electric is equipped with Azure Dynamics' patented Force Drive battery-electric drivertrain technology.
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